Methods and systems to minimize delamination of multilayer ceramic capacitors

Abstract

Methods and systems to improve a multilayer ceramic capacitor using additive manufacturing are disclosed. Conductive layer ends of a multilayer ceramic capacitor may be modified to comprise a round shape, which may increase structural stability of the capacitor's layers. Other configurations may be possible, such as bulbous or wavy shaped conductive layer ends. The layers may comprise one or more pillars made from dielectric material, e.g., barium titanate, disposed through a portion of a conductive layer. The dielectric material may be the same material used in the insulator layers of the capacitor. Each pillar may comprise a plurality of spot connections surrounding its perimeter. The embedded pillars may be used to prevent delamination of the layers and to increase mechanical strength. Additionally, an algorithm of a computing device may determine an optimal shape, size, and/or configuration of the capacitor based on one or more predetermined specifications or properties.

What is claimed is: 
     
         1 . A multilayer ceramic capacitor, comprising:
 a ceramic body;   one or more dielectric layers alternately stacked with two or more conductive layers;   one or more pillars disposed through the two or more conductive layers for preventing delamination of the one or more dielectric layers and the two or more conductive layers,   a pair of external terminations disposed at opposite end portions of the body, and   wherein the two or more conductive layers are alternately coupled to an external termination of the pair of external termination.   
     
     
         2 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein the pillars are aligned in a column when there are two or more pillars disposed in two or more conductive layers.   
     
     
         3 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein a pillar is juxtaposed to another pillar in the horizontal direction when there are two or more pillars disposed in two or more conductive layers.   
     
     
         4 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein a cross-section of the one or more pillars is circular.   
     
     
         5 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein a cross-section of the one or more pillars is an I-beam shape or an elliptical shape.   
     
     
         6 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein a plurality of pillars are arranged in an equilateral triangle tessellation.   
     
     
         7 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein a plurality of pillars are arranged in a polygonal tessellation.   
     
     
         8 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein the one or more pillars comprise a same dielectric material as the one or more dielectric layers.   
     
     
         9 . The multilayer ceramic capacitor of  claim 1 , further comprising:
 wherein the one or more pillars comprise a different dielectric material as the one or more dielectric layers.   
     
     
         10 . A multilayer ceramic capacitor, comprising:
 a ceramic body;   a conductive layer comprising at least one of a base metal and a noble metal;   a dielectric layer comprising barium titanate;   a pillar comprising dielectric material,   wherein one or more dielectric layers are alternately stacked with two or more conductive layers,   wherein the two or more conductive layers are alternately coupled to an external termination of the pair of external terminations, and   wherein an electric field is generated between two juxtapose conductive layers when voltage is applied to the pair of external terminations.   
     
     
         11 . The multilayer ceramic capacitor of  claim 10 , further comprising:
 wherein a pillar super-imposes upon another pillar when the two or more pillars are disposed in two or more conductive layers.   
     
     
         12 . The multilayer ceramic capacity of  claim 10 , further comprising:
 wherein a plurality of pillars are arranged in a regular shape.   
     
     
         13 . The multilayer ceramic capacitor of  claim 10 , further comprising:
 wherein a plurality of pillars are arranged in an irregular shape.   
     
     
         14 . The multilayer ceramic capacitor of  claim 10 , further comprising:
 wherein the pillar comprises a nook for increased structural stability.   
     
     
         15 . The multilayer ceramic capacitor of  claim 14 , further comprising:
 wherein the nook comprises a rounded tip.   
     
     
         16 . The multilayer ceramic capacitor of  claim 14 , further comprising:
 wherein the nook is less than 2 microns in length.   
     
     
         17 . A multilayer ceramic capacitor, comprising:
 a ceramic body;   one or more dielectric layers alternately stacked with two or more conductive layers;   one or more pillars disposed through the two or more conductive layers for preventing delamination of the one or more dielectric layers and the two or more conductive layers,   wherein at least one conductive layer comprises a conductive layer end comprising a round shape for increasing structural stability of the capacitor;   a pair of external terminations disposed at opposite end portions of the body, and   wherein the two or more conductive layers are alternately coupled to an external termination of the pair of external termination.   
     
     
         18 . The multilayer ceramic capacitor of  claim 17 , further comprising:
 wherein a ratio of volume of the one or more pillars to the conductive layer through which it is disposed does not exceed a predetermined value.   
     
     
         19 . The multilayer ceramic capacitor of  claim 17 , further comprising:
 wherein the one or more pillars comprise a round shape.   
     
     
         20 . The multilayer ceramic capacitor of  claim 17 , further comprising:
 wherein a cross-section of the one or more pillars is a triangle shape.